COMPOSITE STRUCTURES WITH EMBEDDED SENSORS

1 . A composite structure of a cargo body, the composite structure comprising:

a core layer including a foam core and a core fiber-reinforced polymer layer;

an outer fiber-reinforced polymer layer adjacent the core layer;

an inner fiber-reinforced polymer layer adjacent the core layer; and

at least one wireless sensor positioned within the foam core and coupled to an inner surface of the core fiber-reinforced polymer layer.

2 . The composite structure of claim 1 , wherein the cargo body includes one of a trailer, a van, a train, and a boat.

3 . The composite structure of claim 1 , wherein the foam core is coupled to the inner surface of the core fiber-reinforced polymer layer via an intermediate layer positioned between the core fiber-reinforced polymer layer and the foam core.

4 . The composite structure of claim 3 , wherein the intermediate layer is a permeable material to facilitate contact between the wireless sensor and the core fiber-reinforced polymer layer.

5 . The composite structure of claim 1 , further comprising a gel coat positioned on at least one of the outer fiber-reinforced polymer layer and the inner fiber-reinforced polymer layer opposite the core layer.

6 . The composite structure of claim 1 , wherein a control system of the cargo body is communicatively coupled to the wireless sensor, the control system configured to receive and process signals transmitted by the wireless sensor.

7 . The composite structure of claim 1 , wherein the composite structure is a single, unitary structure.

8 . A preform for construction of a composite structure, the preform comprising:

a foam core;

a permeable intermediate layer surrounding the foam core;

a fiber-reinforced polymer layer surrounding the permeable intermediate layer; and

a wireless sensor positioned within the foam core and attached to an inner surface of the permeable intermediate layer so that the at least one wireless sensor contacts the fiber-reinforced polymer layer via pores of the intermediate layer.

9 . The preform of claim 8 , wherein the fiber-reinforced polymer layer includes a polymer matrix reinforced with a fiberglass fabric.

10 . The preform of claim 8 , wherein the permeable intermediate layer is a nonwoven fabric.

11 . The preform of claim 8 , wherein the preform comprises a plurality of wireless sensors.

12 . The preform of claim 8 , wherein the permeable intermediate layer is mechanically coupled to the fiber-reinforced polymer layer.

13 . The preform of claim 8 , wherein the foam core comprises a polyurethane foam.

14 . The preform of claim 8 , wherein the wireless sensor is attached to the inner surface of the permeable intermediate layer via adhesive.

15 . A method of manufacturing a composite structure, the method comprising:

providing a fiber-reinforced polymer and a nonwoven fabric;

attaching a wireless sensor to the nonwoven fabric;

providing foam material to the nonwoven fabric and over the wireless sensor relative to the nonwoven fabric;

curing the foam material; and

cutting the composite structure to a predetermined size.

16 . The method of claim 15 , wherein the foam material is a self-curing material.

17 . The method of claim 15 , wherein attaching the wireless sensor to the nonwoven fabric comprises applying adhesive to at least one of the wireless sensor and the nonwoven fabric.

18 . The method of claim 15 , further comprising applying an additional layer of fiber-reinforced polymer to the fiber-reinforced polymer.

19 . The method of claim 18 , further comprising applying a gel coat to the additional layer of fiber-reinforced polymer.

20 . The method of claim 15 , wherein a plurality of wireless sensors is attached to the nonwoven fabric.